Connector Socket Crimping Tolerance Management
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Solution Overview
Problem
Existing electrical connector sockets with crimp connections face manufacturing tolerance issues, leading to inconsistent connections, reduced current-carrying capacity, and poor electrical conductivity, especially when trying to produce a 90° angled version with precise dimensions.
Innovation Solution
The solution involves matching the target diameters of the crimp connector and the connector socket sleeve with a defined slot, allowing for assembly play within the tolerance zone, and using a stamping tool to form a U-shaped annular groove on the crimp connector for a secure connection, ensuring a thick contact flange for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the inner diameter of the connector socket sleeve is precisely controlled to press the laminated contact grid into the sleeve, then the manufacturing precision is improved, but the production complexity and cost increase significantly
Solution Approach 1:
The invention introduces a preliminary expansion of the connector socket sleeve before inserting the laminated contact grid. This preliminary action creates sufficient clearance to accommodate normal manufacturing tolerances, eliminating the need for extremely precise inner diameter control. The expansion is performed right before assembly, ensuring that standard production capabilities are sufficient while still achieving reliable assembly.
2Ease of manufacture
If the wall thickness of the connector socket is reduced to allow easier insertion of the contact grid, then the ease of manufacture is improved, but the mechanical strength and stability deteriorate
Solution Approach 1:
The connector socket sleeve is preliminarily expanded before inserting the laminated contact grid. This preliminary expansion temporarily increases the inner diameter, allowing easy insertion of the contact grid without requiring reduced wall thickness. After insertion, the sleeve returns to its original dimensions, maintaining adequate mechanical strength and stability.
3Manufacturing precision
If the crimp connector passage diameter is precisely matched to the connector socket sleeve outer diameter, then the manufacturing precision is improved, but the assembly reliability deteriorates due to tolerance accumulation
Solution Approach 1:
The connector socket sleeve is preliminarily expanded before inserting the crimp connector. This preliminary expansion creates a clearance that absorbs the accumulated tolerances from both the sleeve outer diameter and the crimp connector passage diameter. As a result, reliable assembly is achieved without requiring extremely precise matching of these dimensions.
4Reliability
If the contact area between the crimp connector and connector socket sleeve is increased to improve current-carrying capacity, then the electrical conductivity is improved, but the device complexity increases
Solution Approach 1:
The invention introduces a movable expansion mechanism that dynamically adjusts the inner diameter of the connector socket sleeve during assembly. This dynamic expansion creates temporary clearance for easy assembly, then returns to a state that ensures optimal contact area between the crimp connector and sleeve. The same mechanism can also provide radial compression to enhance electrical conductivity without requiring a permanently complex structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables a reliable, cost-effective, and high-current-carrying capacity connection between the crimp connector and the cylindrical connector socket sleeve, overcoming tolerance-related manufacturing challenges and ensuring a stable electrical contact.
Implementation Method 1
using a stamping tool, the crimp connector (3) is plastically deformed in such a way that a U-shaped annular groove (11) is formed
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The socket (1) has a cylindrical plug connector socket bush (4) provided with a segment contact grid (2), and a crimp connector (3) provided with a passage web, while an opening is provided in the form of a hole-shaped passage (6). The holder is fixed to an outer casing of the bush by mechanical deformation of an area around the passage such that two circularly running plastic deformed grooves are formed at upper and lower ides of the web. Two circular brackets runs at the bush with interference fit and lie at the bush adjacent to the grooves. An independent claim is also included for a method for manufacturing a plug connector socket.